Industries from food processing to battery manufacturing are seeking innovative solutions to improve the efficiency and purity for producing the ultrafine powders that make up the foundation of these industries. For materials like plant-based proteins—particularly those derived from peas—existing classification methods have proven inefficient, often resulting in low yields, low purity, and excessive energy consumption.
However, recent research by Zaki Hussaini, Design Engineer at Bradley Pulverizer, has shed new light on the ultrafine air classification of pea proteins, offering a more efficient alternative. Hussaini’s work, titled “Ultrafine Air-Classification of Plant-Based Proteins: A Step Towards Reducing Carbon Footprints,” is especially timely in the context of the growing demand for meatless alternative foods and an overall push for sustainable and high-efficiency processing methods.
The Challenge: Separating Proteins from Peas
To produce pea protein powders, peas must first be milled into ultrafine particles—sub 10 microns in size. However, maintaining the purity of the protein while effectively separating it from other components like starch and fiber is challenging. Not only must the proteins be isolated efficiently, but the quality of the product must also be preserved, particularly for food-grade applications where the inclusion of harmful chemicals in the process is unacceptable.
Current classification techniques often rely on chemical methods, which use chemicals that have been linked to cancer. This has led to an industry-wide shift toward mechanical processes like air classification, which offer the same separation efficiency without the risks associated with chemical usage.
The Solution: Bradley Pulverizer’s Stainless Steel Windsifter Air Classifier
For Hussaini’s research, the solution came in the form of Bradley Pulverizer’s SS Windsifter Air Classifier—a stainless steel, food-grade, stand-alone (or integrated) classifier ideal for processing organic materials in sensitive environments. The SS Windsifter allowed for the precise separation of pea proteins from their starch and fiber counterparts.
As a Design Engineer at Bradley Pulverizer, Hussaini has access to the engineering and manufacturing expertise necessary to make this project a success. His aim was clear: optimize the process to achieve the highest levels of purity and yield while maintaining low energy consumption—a critical consideration for scaling up the process to industrial levels.
The Results: High Purity, High Yields, and Low Power Consumption
Hussaini’s research process focused on achieving optimal purity and yield rates while minimizing energy usage. Contrary to many industrial processes, simply scaling up equipment and increasing power consumption does not improve outcomes in this case—in fact, it can be counterproductive. Hussaini’s tests, conducted on lab-scale quantities of pea powder, yielded impressive and scalable results:
- Purity: As high as 70% purity for the classified pea protein powder.
- Yield: Reaching up to 70% yield, with a significant amount of the starch and fiber byproducts remaining useful for other applications.
- Power Efficiency: The SS Windsifter proved exceptionally efficient, with energy rates lower than 0.1 kw power consumed per 1 kg of product processed—ensuring sustainability and reducing the carbon footprint of the process.
These results are not only promising for the food industry, but they also have broader implications including the rapidly evolving battery sector, where the need for higher purity and yield in powders is driving innovation.
The Bigger Picture: Impact on Multiple Industries
One of the most exciting takeaways from Hussaini’s research is the documented proof of the SS Windsifter’s performance, which will directly benefit Bradley Pulverizer’s customers. The results serve as a reference for future applications, enabling more efficient design and engineering of custom air classification systems.
Additionally in the case of peas, the separation of starches and fibers, once considered waste byproducts, is proving to have significant value in various industries. This adds another layer of sustainability to the process, as these byproducts are not discarded but rather repurposed for other uses, creating a circular economy within the process itself.
Looking ahead, the implications of this research extend far beyond plant-based protein production. As industries continue to demand higher-efficiency processes, air classification systems like the SS Windsifter could become the key to unlocking better yields, higher purity, and reduced environmental impact across sectors.
Conclusion: Bridging Innovation with Sustainability
Zaki Hussaini’s research into ultrafine air classification is a prime example of how innovation and sustainability can go hand-in-hand in today’s industrial landscape. By improving the purity, yield, and efficiency of ultrafine powder separation, particularly in the food and battery industries, Bradley Pulverizer is positioned to lead the charge toward more sustainable and scalable processing solutions. This work not only helps meet the demand for plant-based proteins but also creates new opportunities for cleaner, more efficient methods in multiple industries.